Download e-Gladiator Gen 3 Microwave Switch Manual

Sultan Sonar Manual Rev 1.0
A Higher Level of Performance
Manual
Gladiator
Gen 3 Microwave Switch Series
Beam Blockage Detection
Circular Polarisation
For more information, please visit >
www.hawkmeasure.com
>
Table of Contents
Gladiator Gen 3 Microwave Series
Contents
Overview
3
Setup Procedure - Integral System
19
Principle of Operation
Typical Uses
Function
Features
3
3
3
3
Setup Procedure - Remote System
20
Operational Diagnostics
21
Dimensions
4
Remote Main Menus & Interface
22
Remote Microwave System
Weldments and Windows (UHMW / PTFE)
Weldments and Windows (Ceramic)
Weldments and Windows
(Ceramic Tile & Firebrick Assemblies)
4
5
6
Mounting
9
7
General Guidelines
Mounting With Windowed Weldments
Installation With Adjustable Mounting
Correct Mounting Angle
Align Sender and Receiver
9
10
11
12
12
Wiring
13
Remote System Connection HAWK Supplied Cable
Remote System Connection Customer Supplied Cable
Alternate cable type between
Amplifier and Sensors
22
Remote Setup Procedure
23
Quickset Menu - Parameters
App Type - Parameters
Advanced Menu - Parameters
23
24
25
Relay 2 Actions
26
>
Relay 2 Software Flow Chart
27
<
Cross-Talk Prevention / Sequencer Wiring
28
Integral Test Switch
29
Integral Receiver Test Switch Functions
29
13
Troubleshooting
30
14
Error Codes
31
Safety Information
32
FCC Regulations
32
Part Numbering
33
Remote Version
Integral Version
33
34
Specifications
35
14
Functionality Layout - Remote System
15
Wiring
16
Integral System Connection
16
Functionality Layout - Integral System
17
Wiring
18
Wiring - Relay Functions
18
PROPRIETARY NOTICE
The information contained in this publication is derived in
part from proprietary and patent data. This information has
been prepared for the express purpose of assisting operating
and maintenance personnel in the efficient use of the
instrument described herein. Publication of this information
does not convey any rights to use or reproduce it, or to use
for any purpose other than in connection with the installation,
operation and maintenance of the equipment described herein
WARNING
This instrument contains electronic components that are
susceptible to damage by static electricity. Proper handling
procedures must be observed during the removal, installation,
or handling of internal circuit boards or devices:
2
Remote Main Menus & Interface - Remote System
Handling Procedure:
1. Power to unit must be removed prior to commencement of any work.
2. Personnel must be grounded, via wrist strap or other safe, suitable means, before any printed circuit board or other internal devices are installed, removed or adjusted.
3. Printed circuit boards must be transported in a conductive bag or other conductive container. Boards must not be removed from protective container until the immediate time of installation. Removed boards must be placed immediately in a protective container for transport, storage, or return to factory.
Overview
Gladiator Gen 3 Microwave Series
Principle of Operation
Beam blockage
A beam of microwave energy passes from a sender to a separate receiver in bursts approximately 200 times
per second. If the path between the sender and receiver is blocked by any object or material which absorbs
or reflects microwave energy, then the receiver will not be able to detect the signal. The presence or absence
of the signal at the receiver is used to switch a relay for indication or control purposes.
Microwaves are small (Micro) radio waves transmitted from point to point hence the system setup of ‘sender’
and ‘receiver’ units.
>
Typical Uses
<
• Blocked chute detection
• Nucleonic switch replacement
• Collision detection
• High level alarm / Low level alarm
• Stacker / Reclaimer protection
• Truck / machine detection.
• Shiploader protection
Function
The Gladiator Microwave Switch can be used for blockage detection, barrier detection, machine detection,
collision detection for protection, point level measurement, and detection of objects or material between two
points.
Features
• State of the art Circular transmission
• Relay outputs: Integral (1 + failsafe) Remote (2)
• Backwards compatible with all Gladiator Microwave • Remote test function
generations
• Adjustable ON and OFF delays (0-20 sec)
• LCD push button setup / diagnostics on
• Remote 3G HAWKlink connection option
remote amplifier
• Remote amplifier to sensor separation up to
• Simple sensitivity adjustment and calibration on 500 meters (1640ft)
Integral system
• Bright visual status indication on sensors
• Ranges up to 1200 meters (3937ft)
• Independent housing alignment after mounting • Simple ‘1-minute’ setup application pre-sets
sensor.
• Remote sensor or Integral ‘all in one’ types
3
Dimensions
Gladiator Gen 3 Microwave Series
Remote Microwave System
Remote Amplifier
30.7 mm (1.2”)
78 mm (3.1”)
14 mm (0.6”)
192.5 mm (7.6”)
147 mm (5.8”)
131.5 mm (5.2”)
16.2
20.2
30.0
141.5 mm (5.6”)
167.5 mm (6.6”)
190 mm (7.5”)
107 mm (4.2”)
108 mm (4.3”)
174 mm (6.9”)
190 mm (7.5”)
7.5 mm (0.3”)
111.5 mm (4.4”)
192.5 mm (7.6”)
33.0
182.5 mm (7.2”)
Remote Sender / Receiver
33.0
>
158 mm (6.2”)
182.5 mm (7.2”)
4 mm (0.2”)
Integral Sender / Receiver
Ø85 mm (3.3”)
<
Mounting Bracket
Ø85 mm (3.3”)
160 mm (6.3”)
50 mm (2”)
2 mm (0.078”)
90 mm (3.5”)
135 mm (5.3”)
90 mm (3.5”)
4 x 7mm
(0.28”) holes
(A)
129.5 mm (5.1”)
135.5 mm (5.3”)
129.5 mm (5.1”)
135.5 mm (5.3”)
2 mm (0.078”)
Ø88 mm (3.5”)
Ø160 mm (6.3”)
Alignment
marks
160 mm (6.3”)
50 mm (2”)
29.0
147 mm (5.8”)
50 mm (2”)
74 mm (2.9”)
29.0
4 x 10mm
(0.375”) holes
Ø88.5 mm (3.5”)
Ø88 mm (3.5”)
Ø160 mm (6.3”)
MA15 / MA25 Focaliser Tube (extension pipe)
MA20-P1
300mm (11.8")
75mm (2.95”)
4 x 10mm (0.375")
MA12 / MA13 Adjustable Mounting Bracket
2" N.P.T.
6.50mm
(0.25”)
100mm (3.94”)
336mm (13.2")
148mm (5.83")
225mm
(8.85")
120mm (4.72")
135mm (5.3")
4 x 10mm
(0.375") Ø
4
2x
End closed
with UHMW
window
135mm (5.31")
67mm (2.6”)
(A)
101mm
(3.97")
35mm
(1.38”)
(A)
(A) 95mm
(3.75”)
160mm (5.51")
4" NPT THD
4 x 7mm
(0.28")
Dimensions
Gladiator Gen 3 Microwave Series
Weldments and Windows (UHMW / PTFE)
Weldment with UHMW / PTFE Windows
Weldment is welded to the vessel. Window threads into Weldment
Window
G
E
A
F
Weldment
>
B
<
C
D
Size
A
B
3”
100
(3.94”)
3”
NPT
125
(4.92”)
4”
NPT
4”
F
6”
190.4
(7.5”)
6”
NPT
C
D
E
(0.87”)
(0.2”)
24.4
(0.96”)
5
(0.2”)
G(0.25”)
Ø 6.5mm
22
5
2 Places
A
40
B(3.94”)
E
5
(0.2”)
C
UHMW / PTFE Window
75mm (2.95")
Ø 6.5mm (0.25”)
2 Places
I
75mm (2.95")
D
F
G
92.5
(3.64”)
118
(4.65”)
4
(0.16”)
Part
Number
Size
120
(4.72”)
148
(5.83”)
4
(0.16”)
MA0
3”
MA3
3”
MA4
4”
MA5
6”
MA6
3”
H
175
(6.89”)
I
223
(8.78”)
15mm (0.59")
H
Size
H
I
MA7
4”
3”
3”
NPT
28.7
(1.13”)
MA8
6”
4”
4”
R
NPT
35
(1.38”)
MA18
4”
MA19
3”
6”
6”
NPT
40
(1.57”)
MA20
4”
MA21
3”
MA22
N OP Q
4”
15mm (0.59")
J
K
R
5
11.2
(0.44”)
Weldment / Window Parts
L
Window








Weldment










C C
D
Dimensions
C
D
D
Gladiator Gen 3 Microwave Series
H
Ø 6.5mm (0.25”)
2 Places
H
H
Ø 6.5mm (0.25”)
Ø 6.5mm (0.25”)
2 Places
2 Places
Weldments and Windows (Ceramic)
Weldment with Ceramic Windows
I
15mm (0.59")
75mm (2.95")
Weldment
is welded to the vessel. Window is locked into Weldment with Locking Retainer
Locking
75mm (2.95")
Retainer
I
I
Weldment15mm
Window
R
K
3”
100
(3.94”)
3”
NPT
4”
125
(4.92”)
4”
NPT
L
M
MA17
4”




T
U
V
92.5
(3.64”)
118
(4.65”)
4
(0.16”)
75
(2.95”)
65
(2.56”)
3”
NPT
74.5
(2.93”)
101
M
(3.98”)
120
(4.72”)
148
(5.83”)
4
(0.16”)
100
(3.94”)
90
(3.54”)
4”
NPT
100.5
(3.96”)
24.4
(0.96”)
5
(0.2”)
>
<
22
5
65
75
Ø 6.3mm (0.25”) U
2 Places
(0.87”) (0.2”) (2.56”)L (2.95”)
N
90
(3.54”)
L
M
V
Ceramic Window
U
Ø 6.3mm (0.25”)
2 Places
Ø 6.3mm (0.25”)
U
12.3mm (0.48”)
2 Places
S
T
6
3”
Weldment
N OP Q
Locking Retainer
11-12.7mm (0.43-0.5”)
V
T
12.3mm (0.48”)
S
MA16
Window
R
T
S
Size
JMN O P Q
N OP Q
KP
O
Q
R
S
K
K
Part
Number
L
J
J
15mm (0.59")
R
J
Size
Weldment / Window Parts
(0.59")
75mm (2.95")
11-12.7mm (0.43-0.5”)
12.3mm (0.48”)
11-12.7mm (0.43-
Dimensions
Gladiator Gen 3 Microwave Series
Weldments and Windows (Ceramic Tile & Firebrick Assemblies)
Weldment with Ceramic Windows
Weldment is welded to the vessel. Window is locked into Weldment with Locking Retainer
Weldment / Window Parts
Part
Number
Size
MA9
Special
MA10
Special
MA16
3”
MA17
4”
Window
Weldment








Mounting Assemblies
152.4mm (6.0")
215.9mm
(8.5")
101.6mm
(4.0")
50.8mm
(2.0")
317.5mm (12.5")
Ceramic Tile
101.6mm (4.0")
Firebrick
152.4mm (6.0")
7
25.4mm (1")
114.3mm
(4.5")
228.6mm (9.0")
76.2mm
(3.0")
>
<
Dimensions
Gladiator Gen 3 Microwave Series
Adjustable Microwave Bracket
MA-12 - With UHMW Window
MA-13 - With PTFE Window
135mm (5.3")
4 x 10mm (3/8") Ø
Mounting holes
>
<
225mm
(8.85")
120mm (4.72")
148mm (5.83")
336mm (13.2")
Flanged Pipe Mount MA-15
140mm (5.51")
300mm (11.8")
2" N.P.T.
101mm
(3.97")
135mm (5.31")
19.9mm (0.78")
6.3mm (0.25")
4 mounting holes 10mm (3/8")
8
End closed
with UHMW
window
Flanged pipe mount
94mm
(3.7")
recommended for long
range applications
Mounting
Gladiator Gen 3 Microwave Series
General Guidelines
1. When looking for a mounting location it is
important to locate and mount the interior of

the window/sensor face for each unit flush with the vessel wall and where minimal build-up will occur. The system can penetrate through
generous amounts of buildup of various products,
Do not mount
with cavity
however, the better the position, the more reliably
it will operate. A cavity in the vessel mount
position where build up is possible will result in a
>
‘plug’ forming in front of the beam path resulting in
unit performance issues.

2. Microwave energy cannot penetrate through steel
linings or other conductive linings. You must cut
a viewing hole and use an appropriate windowed
weldment.
<
Do not mount
where sensor can
be damaged by
material
3. For high vibration applications, it is necessary to Produc
isolate the electronics to keep them from long term

damage. This is most often accomplished using 4”
UHMW or Teflon windowed weldments in the
vessel walls, and mounting the Microwave Sender
and Receiver to a separate stable structure
Mount flush
with wall in safe
location
(I-beam, handrail) to isolate them from vibration.
Hopper
Isolation shock mounts can also be provided to
help protect the electronics.
Product Flow
4. For high temperature applications which exceed
65°C/150°F (precipitators, cement cyclones, etc.),

it is necessary to ensure that the sensors always
remain below 65°C/150°F. This is normally
achieved by installation of temperature resistant
windows of ceramic or firebrick, and positioning
windows, and set back far enough that their
Product Flow
temperature remains below the given limit.
Hopper/Feeder
X
Hopper/Feeder
Sending Unit
of the Sender and Receiver in line with the
9
Mount behind
flush Window/
Weldments
X
Isolation Mount
X
X = 30° Max
Mounting
Gladiator Gen 3 Microwave Series
General Guidelines
4. When mounting to monitor the level of a flowing product such as coal, ore or wood chips,
position the microwave path out of the direct
product flow stream. If at all possible, go behind
the flow stream or well in front of it. This will
minimise any possibility of unwanted trips due to
abnormal product flow blocking the beam. Always
use the recommended setup for blocked chute detection.
>
5. When using the system as a proximity switch such as truck detection the mounting arrangement is application dependent and must ensure proper operation even under worst case conditions.

Mount away
from main
product flow
Mounting With Windowed Weldments
Windowed Weldments are designed to protect the Microwave from the hazards of the application. The
weldment is welded to the chute/application wall, and then the window is threaded or locked into position. The
Microwave pulse will pass through plastics and ceramics. However it will not pass through metallic type lining.
Metal Bin/Chute Walls
Sender
10
4” UHMW Windowed Weldment
Receiver
<
Mounting
Gladiator Gen 3 Microwave Series
Installation With Adjustable Mounting
Mounting of a Microwave system on sloped vessel
to help protect the electronics from damage. Each
walls can be accomplished using the Microwave
side wall of the vessel must not exceed 30 degrees
Adjustable Mount (MA-12 or MA-13). This system
from the vertical centerline. To mount the adjustable
allows the microwaves to be mounted to a sloped
bracket, simply cut a hole and weld the 4” weldment
surface and then adjusted horizontally for optimum
directly to the vessel, install the window, mount the
performance and operation. The adjustable mount
microwave and adjust horizontally.
has an integral 4” weldment with UHMW polyethylene
or PTFE (Teflon) window options. An option with the
bracket is a vibration isolation kit (shock mounts)
>
<
Product Flow
Hopper/Feeder
X
X
Sending Unit
Isolation Mount
Adjustable microwave mounting bracket
MA-12 or MA-13 welded to vessel wall.
UHMW (MA-12) or Teflon (MA-13) Window.
11
X = 30° Maximum
Receiving Unit
Mounting
Gladiator Gen 3 Microwave Series
Correct Mounting Angle
Correct Elevation
Maximum Signal Strength to Receiver is indicated by maximum brightness of
Green LED on Receiver.
Sending Unit

Receiving Unit
Microwave Beam
Housing can be rotated
within 200º after the
mounting thread is
tightened, to allow cable
entries to face downwards
or allow optimal cable
clearance.
Incorrect Elevation
<
Sending Unit
Receiving Unit

Align Sender and Receiver
Rotate so that Visual Alignment Guide is in the same position on both sender and receiver.

12
>
Wiring
Gladiator Gen 3 Microwave Series
Remote System Connection - HAWK Supplied Cable
• The black wire of HAWK supplied cable comes with one end GND and the other GND / SHLD together.
• The GND / SHLD end is a larger cable which has been heat shrunk. The GND only end is the same size as the other cables.
• The GND / SHLD end must be connected to the amplifier.
Sender / Receiver
(GND only end)
Amplifier
(GND / SHLD end)
Remote Sender
>
Remote Receiver
<
Use long nose
pliers to extract
terminals
• Press and hold to test level relay action
13
30
9
10
11
12
13
14
15
– +
DC-In
AC-In
BROWN
SENSOR
B
8
WHITE
+ –
4-20mA
7
COMMS
Remote Receiver
**Ground the housing to vessel if vessel is
metallic. G
round the housing to plant ground if
vessel is non-metallic.
BLU
RED
6
7
NO
COM
NC
NO
TEST IN
COM
NC
MASTER OUT
SLAVE IN
BROWN
BLACK
18
19
20
21
22
23
24
25
26
27
28
29
30
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
L1
29
N
28
4-20mA
SENSOR
A
27
6
5
Status LED
Sender
• Green when powered
• High illumination = strong signal
illumination =–weak
+ signal
–
+• Low
17
B
26
5
4
RELAY 2
BROWN
25
**
RELAY 1
WHITE
24
4
3
BLUE
23
BLUE
3
2
Add wire between
terminalGround
8 andscrew
ground screw
Remote Receiver
NO
COM
NC
NO
COM
TEST IN
NC
22
RED
2
1
16
Sender
1
10
BLACK
21
MASTER OUT
SLAVE IN
BROWN
BLACK
20
L1
19
9
MIC-SENDER
RELAY 2
N
18
RELAY 1
A
TEST Button
17
8
Inputs model dependent
BLACK
• Solid while not transmitting
16
Is
Status LED
• Green when powered
• Blinks while working correctly
RED
Remote Sender
7
Gladiator Remote Amplifier
Inputs model dependent
MIC-SENDER
6
4
10 5
Ground screw
**
Gladiator Remote
Amplifier
**
39
Add wire between
terminal 8 and
ground screw
Add wire between
Ground screw
terminal 8 and
ground screw
Ground screw
6 1 7 28
WHT
5
BRN
4
BLK
3
RED
2
BLU
1
WHT
10
RED
9
STATUS
Signal
RED
8
BRN
7
6
BLK
5
Is
4
remote
STATUS
microwave sender
RED
3
STATUS
Signal
BRN
2
BLK
1
microwave sender
RED
BRN
STATUS
COMMS
Signal Contact
DC-In
AC-In
Remote Receiver
• Signal can be read with voltmeter across Signal contact point and earth screw (or other ground reference)
**Ground the housing to vessel if vessel is metallic.
Ground the housing to plant ground if vessel is non-metallic.
• 2.4-2.5V is full signal.
0V is no signal
Wiring
Gladiator Gen 3 Microwave Series
Remote System Connection - Customer Supplied Cable
Remote Sender
Remote Receiver
Use long nose
pliers to extract
terminals
7
8
9
10
1
2
3
BLK
6
RED
5
BLU
4
WHT
3
remote
STATUS
Signal
BRN
2
BLK
1
microwave sender
RED
BRN
STATUS
4
5
6
7
8
9
10
>
<
Shielding to
ground screw
Gladiator Remote Amplifier
25
NO
24
COM
23
NC
22
26
27
28
29
30
10
11
12
13
14
15
– +
N
TEST IN
NC
21
NO
MASTER OUT
20
COM
SLAVE IN
19
DC-In
AC-In
4-20mA
5
6
7
8
9
WHITE
4
BLUE
3
RED
2
+ –
BLACK
1
SENSOR
COMMS
L1
Sender
• Press and hold to test level relay action
BROWN
18
RELAY 2
A
TEST Button
17
Is
• Solid while not transmitting
16
BLACK
Remote Sender
RELAY 1
RED
MIC-SENDER
Status LED
• Green when powered
• Blinks while working correctly
Ground
screw
**
Inputs model dependent
B
Ground
screw
BROWN
**
Shielding to
ground screw
Remote Receiver
**Ground the housing to vessel if vessel is
metallic. G
round the housing to plant ground if
vessel is non-metallic.
Alternate cable type between
Amplifier and Sensors
Remote Receiver
Status LED
• Green when powered
• High illumination =
strong signal
• Low illumination = weak signal
Signal Contact
• Signal can be read with voltmeter across Signal contact point and earth screw
(or other ground reference)
• 2.4-2.5V is full signal.
0V is no signal
Alternate Cable Colour Equivalents
Pairs
HAWK
Belden 3120A
Dekoron
• 6 or 8 conductor (5 used) shielded twisted pair instrument cable.
Pair 1
Red
Black
Red
Black
White 1
Black 1
• Conductor size dependent on cable length.
Pair 2
White
Blue
Yellow
Green
White 2
Black 2
Pair 3
Brown
---
Brown
White (not used)
White 3
Black 3 (not used)
Pair 4
not used
not used
not used
• BELDEN 3120A, DEKORON or equivalent.
• Max: BELDEN 3120A = 500m (1640 ft).
3 pairs, 1 conductor not used.
14
remote
STATUS
3
Signal
Functionality Layout - Remote System
1
2
3
4
5
6
7
8
9
10
9
10
Gladiator Gen 3 Microwave Series
Functionality Layout - Remote System
1
4
Calibrate button
1
CAL
STATUS
microwave sender
RUN
1
2
3 RELAY
4 1 5
6
7
RELAY 2
8
9
10
STATUS A
STATUS B
3
5
2
7
HI
FSH
CAL TEST
ON
ON
Down button
3
Delay
Sensitiv
ity
Run button
2
12
4
LO
Up button
5
Relay LEDs 1 and 2
6
Display (LCD with backlight)
>
7
Status LEDs A and B
<
6
1
2
3
FSL
4
OFF
12
Signal
5
6
OFF
7
8
- Status A flashes with signal transmission of a unit in
Remote or Master mode.
- Status B flashes with signal transmission of a unit in
Master or Slave mode.
**
**
3
4
5
7
8
9
10
10 3
9
SignalSignal
1
LO
21
3
2
6.
CAL TEST
7.
8. 9. 10.
FSH
ON
12
FSL
43
ON
12
STATUS
OFF OFF
RED
7 microwave
8
9 10 sender
6
HI
5.
BLUE
6
4.
BLK
5
RED
BLU
4
3.
54
6
5
remote
BLACK
2
WHT
3
2.
WHITE
1
2
BRN
1
1.
Sensitiv
remote
ity
Delay
8
9
TRANSDUCER
3
STATUS
7
4
REMOTE RECEIVER
TERMINAL BLOCK 8
2
STATUS
6
Receiver
4 5
1
BROWN
Sender
76
87
9
8
10
9
10
Terminals 1, 2, 3, 9, 10 not used.
8
GREEN LED: Power / Received signal strength.
Brightness varies with strength of received signal.
9
Removable terminal block - plug in type
(1) Sender status LED
(3) Signal contact
• Signal can be read with voltmeter across Signal contact point and earth screw (or other ground • Blinks while working correctly
• Solid while not transmitting
reference). 2.4-2.5V is full signal. 0V is no signal.
• Clear indicates no power
(4) Receiver status LED
y
STATUS
Sensitiv
• Press and hold to test level relay action
CAL signal
TEST
• Low illuminationHI forFSHweak
ON
• Clear indicates no power
microwave sender
LO
Signal
15
1
2
3
4
5
6
7
8
9
10
1
2
3
12
FSL
4
5
ON
OFF
6
Delay
it
• High illumination
for good signal
(2) TEST button
12
OFF
7
8
9
10
remote
STATUS
3
Wiring
Signal
Gladiator Gen 3 Microwave Series
1
2
3
4
5
6
7
8
9
10
Integral System Connection
Sender
Integral Receiver
Use long nose
pliers to extract
terminals
Sensitiv
HI
microwave sender
2
3
4
5
6
7
8
9
10
1
2
CAL TEST
ON
LO
Signal
1
FSH
ON
12
FSL
3
4
Delay
STATUS
ity
OFF
5
6
12
OFF
7
8
9
10
>
The AC earth /
ground-cable must
be connected to the
ground screw inside
the housing when
using AC power.
Ground
Screw
**Ground the housing to vessel if vessel is metallic.
on-metallic.
G round the housing to plant ground if vessel is n
Ground
Screw
**
<
Sender
1
Status LED
• Green when powered
• Blinks while working correctly
2
**
Integral Receiver
6
Status LED
5
7
8 strength
• Green LED:
4 Indicates received signal
• High illumination = strong signal
9
TEST Button
Stays illuminated if calibration fails.
Sensitiv
• Low illumination = weak signal
ity
• Red3LED: Indicates
Relay status
• Blue LED: Flashes
calibration.
HI during
FSH
CAL
TEST
STATUS
microwave
sender
• Press and hold to test level relay
action.
1
2
3
4
5
6
7
8
9
Signal
Signal
10 Contact
LO
ON
12
FSL
OFF
12
OFF
• Signal can be read with voltmeter across Signal
1 2
3 4 5
6 7 8
9 10
contact point and earth screw
(or other ground reference)
10
SENDER TERMINAL LAYOUT
DC-IN
ON
Delay
• Solid while not transmitting.
AC-IN
• 2.4-2.5V is full signal. 0V is no signal.
Note:
DC-IN
A
B
+
-
N
L1
6.
7.
8.
9.
10.
10.
COMMS
5.
4. Test
NO
3.
L1
9.
1.
NC
N
8.
12-30VDC 80-260VAC
Terminals 1, 2, 3, 4, 5, 6 not used
RELAY
2. COM
+
-
7.
6.
5.
4.
3.
2.
1.
RECEIVER TERMINAL LAYOUT
RS 485
AC-IN
12-30VDC 80-260VAC
AC power terminals may only be used when universal AC power supply option has been selected see part numbers - AC terminals have no function in products without universal AC power option.
16
Functionality Layout - Integral System
HI
STATUS
Gladiator Gen 3 Microwave
Series
microwave sender
LO
Signal
1
2
3
4
5
6
7
8
9
10
FSH
ON
1
2
12
3
FSL
4
5
Delay
Sensitiv
ity
CAL TEST
ON
OFF
6
12
OFF
7
8
9
10
Functionality Layout - Integral System
**
Sender
1
2
3
4
5
6
7
8
9
8
10
Sensitiv
ity
HI
LO
Signal
10
1
2
3
FSH
ON
12
FSL
4
5
Delay
1
7
9
3
microwave sender
6
5
4
2
STATUS
**
Receiver
CAL TEST
ON
OFF
6
>
12
OFF
7
8
9
10
(1) Sender status LED
(7) Cal Mount switch
• Blinks while working correctly.
• Solid while not transmitting.
• Cal mount conducts the automatic setup routine for the
system. Perform Cal mount for all new installations, and
after adjusting either Sensitivity pot or Hi/Lo switch.
(2) TEST button
• Press and hold to test level relay action.
(3) Sensitivity dial
• Turn clockwise for switching in clean environments and object detection.
• Turn counter-clockwise for difficult applications, dusty/
wet environments.
(4) Hi / Lo switch
• Hi mode for clean environments and object detection.
• Lo mode for difficult applications, dusty/wet environments.
• Switch up to initiate Cal mount, wait several seconds,
then switch back down. Unit will automatically complete Cal mount routine.
(8) Test switch
• Can be used for a failsafe / test relay. See full manual for further information.
(9) Delay pot
• Rotate clockwise to increase Relay on/off delay time.
15 Sec
• FSH relay normally closed.
• FSL relay normally open.
(6) Receiver status LEDs
• Green - High illumination for good signal,
Low illumination for weak signal.
• Red - Relay indication. Illuminated when closed.
• Blue - Cal mount indication - flashes during Cal mount, will stay illuminated if Cal mount fails.
17
2.5 Sec
Delay
(5) FSH / FSL switch
0.5 Sec
(10) Signal contact
• Signal can be read with voltmeter across Signal contact point and earth screw (or other ground reference). 2.4-2.5V is full signal. 0V is no signal.
<
Wiring
Gladiator Gen 3 Microwave Series
Wiring - Relay Functions
Switch contact actions.
Relay - for Smart Integral Probe Version
Relay Action
Relay 1 - for Remote Version
State 1
FailSafe Low
FSL
FailSafe High
FSH (default)
Relay Status
1
2
3
NC COM NO
1
2
3
NC COM NO
Smart Integral
Receiver terminal
numbers
Remote Amplifier
terminal function
labels
>
LED Status
<
State 2
Material level rising
1
2
3
NC COM NO
1
2
3
NC COM NO
1
2
3
NC COM NO
1
2
3
NC COM NO
1
2
3
NC COM NO
1
2
3
NC COM NO
NC COM NO
NC COM NO
NC COM NO
NC COM NO
State 3
Material detected
Material level falling
POWER FAILURE
FailSafe Switch Contact Action
Relay 2 - Remote version only. For Smart Integral
units, the Test terminal can act as a solid state
POWER FAILURE
OR
INTERNAL FAILURE
output with a similar function.
SYSTEM OPERATING
NORMALLY
18
Setup Procedure - Integral System
Gladiator Gen 3 Microwave Series
Setup Procedure - Integral System
1. Mount the units according to
Mounting Guidelines
1.1 If units are AC powered ensure proper grounding
is connected to ground screw.
2. Make sure that the material or target is not blocking the path between sender and receiver.
3. Turn the power on
The green LED on the sender and receiver will stay
on permanently to indicate that power is on. Green
LED on receiver varies in brightness with strength of
received signal.
4. Select the required relay action
The Relay can switch ‘ON’ (FSL) or ‘OFF’ (FSH)
as the microwave beam is blocked. Set the relay
action selection switch position depending on your
requirements. FSH is recommended (ordinarily
on/energised, switches off/DEN during blocked
conditions).
6. Select the sensitivity
There are two adjustments controlling the sensitivity
of the switch point:
6.1 The ‘HI/LO’ sensitivity switch is used as the
primary sensitivity setting. Select LO sensitivity
for Blocked Chute detection and if build-up is
expected over sensors. Select HI sensitivity for clean
environments and lighter/less absorptive material or
targets. LO recommended for most applications.
6.2 The sensitivity dial
Turning the pot fully counter-clockwise factory
recommended for blocked chute applications. If
operating in HI mode set the pot to 12 o’clock. In this
mode you can turning the pot clockwise to reduce the
amount of beam blockage required for switching and
vice versa.
19
7. Select the relay time delay
Full anti clockwise is minimum (0.1 seconds). Full
clockwise is maximum (20 seconds). Adjust as
required allowing time to avoid possible nuisance
trips. The selected delay will be used for both an ON
delay and an OFF delay.
8. Perform a CAL mount
Do not proceed with this step unless the material or
target position is well beneath the line between the
sender and receiver.
Switch CAL switch on the Receiver unit to ON
position. The Blue LED will blink to indicate that
mounting calibration is now in progress. Wait 5
seconds, then switch the mounting calibration switch
to ‘OFF’ position.
The blue LED will switch off after successful
calibration. If it stays on this indicates there was
a calibration error. If this is the case please check
that the path between sender and receiver is clear
and alignment is correct. You may need to lower
the Sensitivity setting. Try the calibration again. If
mounting calibration was successful the blue LED
should be off and the Green LED should be ON.
9. Switch check
If required block the Sender with a sample of the
application material (note the units are capable of
penetrating significant amounts build up). The green
LED will dim when the Microwave beam begins to be
blocked.
You can also press the ‘TEST’ button on the Sender
to simulate a blocked chute condition and thus trigger
the relay action.
Note: Integral type Microwave systems should not
be used for anti collision detection / boom protection
applications where there is limited access to the
electronics. Contact Hawk for information about the
remote type systems.
>
<
Setup Procedure - Remote System
Gladiator Gen 3 Microwave Series
Setup Procedure - Remote System
1. Mount the units according to Mounting Guidelines
To protect from surges, ensure that an external ground wire is connected between the outside ground screw on the Gladiator housing and the vessel or other ground source.
2. Make sure that the material or target is not blocking the path between sender and receiver.
3. Choose Application Type (App Type)
Selecting the App Type sets the unit to pre-sets specific for blocked/plugged chute detection, boom protection (long range machinery collision detection) and several others.
A) Alignment - For aligning the unit at long range. Unit is set to 1.2V signal (~48% switch value on display), move the unit face to get the volt reading high (2.4V will be the maximum reading or 0% switch value). Calibrate & re-select this mode and repeat till you cannot improve the alignment.
Sensor Value
Press
B) Blocked Chute - Configures the unit for blocked chute applications.
E) Analog (Density) - Special measurement mode. See App Types for further information.
4. Perform Cal Mount
Some App Types require a Cal Mount. This calibrates the system to ignore any interference
caused by mounting etc. There should be clear path between the sender and receiver.
Select ‘Yes’ to start the mounting calibration. ‘Wait’ will be displayed during the calibration for
up to 30 seconds. Unit is now able to cancel the influence of the mounting. The % reading on
the back lit display will be zeroed with the existing process conditions and the measurement
history log has been cleared.
Always calibrate the unit after adjusting the App Type.
5. Select Switch Point
The output relay will switch when the Switch% exceeds the entered value. The default value
of 76% will be suitable for detecting most media. For detection of products which are less
absorbent of Microwave energy, select a lower % value and vice versa. For highly absorbent
materials, almost any setting will work, but higher % settings will be more immune to build
up. When the level or target falls below the sensors the relay will switch back at half of the
entered switch point % value (when the beam is no longer broken).
CAL
QuickSet
C) Boom Protection - Configures the unit for anti collision applications
D) Switch - Allows selection of Sensitivity% for typical level switch application. The higher the programmed %, the more responsive the unit will be. Use a lower % if build up or dusty conditions are expected.
CAL
UnLock
0
Press
Press
CAL
Cal Mounting
Yes / No
Press
CAL
Press
CAL
Yes
Switch Point
76%
Press
CAL
Press
CAL
50%
Delay Adjust
2.0S
Press
CAL
Press
CAL
0.1S
Relay Action
FailSafe Hi
Press
Press
Twice
CAL
RUN
FailSafe Hi
FailSafe Low
6. Set Delay
Set the time delay to be used for both switch on and switch off action.
7. Choose Relay Action
The Relay can switch ‘ON’ or ‘OFF’ as the microwave beam is blocked and switch ‘ON’ or ‘OFF’ in response to an
instrument failure. Failsafe Hi for normally closed relay, failsafe Low for normally open relay.
Note: Older software revisions may have different parameters or menu structure
20
>
<
Pre
Press
CAL
App Type
Blocked Chute
Press
S
Pre
Operational Diagnostics
Gladiator Gen 3 Microwave Series
Operational Diagnostics
Diagnostic
Description
Sensor
Sensor value indicates the amount of signal blocked from
Value
0-100%. 0% is full signal, 100% is complete blockage.
Notes
For the level relay to switch to state '2', the Sensor value
SW On
must exceed this SW On % for the duration of the on delay
time.
SW Off
For the level relay to switch to state '1', the Sensor value
Switch mode 'Auto' will
must drop below this SW Off % for the duration of the off
automatically set the SW Off
delay time.
% to 2/3rds of SW On %
Max
The maximum recorded Sensor value % since last log reset
Min
The minimum recorded Sensor value % since last log reset
Delay
Dynamic switch delay time indication
Temp
Measured temperature inside Receiver unit
• Normal
• Unit in normal operation
• Recover
• Unit applying 'Recover' Gain to retain or enhance signal
• Failed
• Unit is in failsafe condition
<
Unit will indicate Recover
commonly for blocked
chute and other switching
applications.
Signal strength measured at the Receiver.
Signal
This value is proportionate to the Sensor Value %:
In most modes the unit will be
• 0V = Sensor Value 100%. No Signal
looking to hold a 2.5V signal.
• 1V = Sensor Value 50%. Half Signal
2.0V to 2.5V is used for signal
• 2.0V = Sensor Value 0%. Full Signal
stability purposes.
• 2.0V to 2.5V = Sensor Value 0%. Full signal
Recover
Gain
Noise
Recover Gain % applied. Recover Gain is used retain the
incoming signal during difficult conditions.
will have pre-defined amounts
of Recover Gain available.
(Calibrated Gain plus Recover Gain) applied by the system.
Noise interference in V - Noise from interfering received
It is normal to see a small
frequencies or along the communications wiring.
consistent amount of Noise.
• Remote: (default). Standard remote system
• Master
• Master: Unit mode is set as 'Master' for cross-talk prevention
• Slave
• Slave: Unit mode is set as 'Slave' for cross-talk prevention
21
The programmed App Type
Gain % applied. This is the total Gain
• Remote
>
Remote Main Menus & Interface
Gladiator Gen 3 Microwave Series
Remote Main Menus & Interface - Remote System
Note: Parameters may vary depending on older software revisions
CAL
Press
Sensor Value
0%
Press
Default Unlock
code = 0
22
Select / Edit / Save
RUN
Run / Return
CAL
QuickSet
Standard parameters
Advanced
Advanced parameters
Scroll up / down
>
<
Press
i
ow
CAL
CAL
UnLock
0
Press
To view Operational
Diagnostics
Remote Setup Procedure
Gladiator Gen 3 Microwave Series
Quickset Menu - Parameters
Parameter
App Type
(see next page for
additional information
about Application Types)
Description
Options
Select application pre-set. This automatically
• 4-20mA (Density)
configures the unit to the recommended settings
• Switch
for each specific application.
• Boom Protect
Note: you must perform a Cal Mount after
• Blocked Chute
changing or selecting App Type
• Alignment
Performs a Cal Mount in which the unit
Cal Mounting
automatically configures itself based on the
• Yes / No
<
selected App Type and the mounting environment.
Switch Point
This is the switch on / off sensor value % for relay
• Auto - 75% (on) 50% (off)
actions
• Manual (set in Advanced)
Set on delay time for the first relay. If using the
On Delay Adj
2nd relay in cleaner / maintenance mode 1/2 of
• Adjustable in seconds
this value will be the duration of the relay timer
Relay1Action
Lock Code
23
>
Adjust the Relay action to be energised or
• FailSafe Hi
de-energised during normal operation
• FailSafe Low
Set a lock code to prevent unauthorised access
• Default 0
Remote Setup Procedure
Gladiator Gen 3 Microwave Series
App Type - Parameters
App Type
Description
Sub Menu
HiSpan%
Analog
(Density)
(see Density
Setup Guide
below)
Analog is the new App Type which allows customers to
measure variation in the amount of Microwave energy
blocked and absorbed by on application.
The variance is represented by a 4-20mA analog output.
Note: Relay1 as a switch function is disabled while the
Density application is selected.
This is the 20mA reference point.
This can be Viewed, Autoset or set to a
Custom value.
This value will always be a 10-100%
with 10% the most sensitive 100%
suited to measure the indicate the
widest variation.
Sensitivity%
Switch
Sets the unit to a standard switch mode with adjustable
sensitivity
A high value will make the unit more
sensitive to switching and responding to
lighter materials.
A low value will make the unit more
resilient and ignore dust / build up.
Boom
Protection
Blocked
Chute
Alignment
Sets the unit to Boom Protection mode.
This can also be used for machinery / truck or object
detection & collision avoidance.
Sets the unit for blocked chute mode.
Note: This mode may be unsuitable for very low dielectric
materials.
A mode to assist aligning units over long range. Select
this mode and perform a Cal Mount. RUN the unit and
it will indicate half signal / approximately 48 Switch% on
the display. Improving the alignment will reduce the %
with the goal to reduce as low possible. Re Cal-Mount
if the % reaches 0 and continue to adjust the alignment
until it cannot be improved further.
After using this mode you must set the unit back to a
normal app type as function is purely for alignment.
Analog (Density) Setup Guide
1. Select ‘Analog' (Density) App Type
2. To set the 4mA condition reference - Perform a Cal Mount. HAWK recommends this should be done with Clear Path between Sender and Receiver.
3. Press RUN several times to restart the unit.
This will be the 4mA reference point for the analogue
Note: You must RUN the unit before proceeding with the next step
24
To set the 20mA reference point you can either:
4. Enter a specific ‘HighSpan%’ (10-100%) or;
5. Start the process you wish to measure. When the desired density of product is between the Sender & Receiver you can enter the Quickset menu and run ‘Autoset’. This sets the measured condition between Sender and Receiver to the 20mA / 100% reference.
If Autoset returns ‘Failed’ you either did not press RUN after the Cal Mount to set the 4mA point or the Microwave pulses are not blocked by a high enough density which the unit can detect.
>
<
Remote Setup Procedure
Gladiator Gen 3 Microwave Series
Advanced Menu - Parameters
Parameter
Switch Mode
Description
Sub Menu
• Auto - Switch On% set in Quickset,
Switch Off% automatically configured
• Switch On%
• Manual - Manually adjust Switch On and Switch Off %
• Switch Off%
• Off - Switch mode disabled in Analog (Density) mode
Set Relay2Action as one of the below:
• Failsafe - Relay2 triggers on failsafe conditions
• Relay2 - Mirrors Relay1 action to act as a second / backup
relay for the system
Relay2Action
• Maintnce Chk* - Triggers Relay2 at a pre-defined Gain value
for a maintenance / build up alarm
• GainOPpt Cln* - Triggers Relay2 to activate a cleaner system
based on total Gain used
* For further information about
the Maintenance and Cleaner
Relay2 alarms see 'Relay 2
Actions' on next page
• TimeOpt Cln* - Triggers Relay to activate a cleaner system
based on a programmed time delay
View Log
Reset Log
Sets the unit to Boom Protection mode. This can also be used
for machinery / truck or object detection & collision avoidance
Sets the unit for blocked chute mode. Note that this mode may
be unsuitable for very low dielectric materials.
• DeviceNet (not functional)
Comms Type
Adjust & select additional communications, baud rate and
• Profibus (not functional)
device ID. All GSA units by default include Modbus.
• HART (not functional)
• Modbus
Back Light
Operating
Mode
Turn on / off LCD backlight
• Remote: Default setting for standard remote system
For further information see
• Master: Set system to Master mode for 2 system anti-crosstalk
'Cross Talk Prevention /
• Slave: Set system to Slave mode for 2 system anti-crosstalk
Sequencer Wiring' section
Display Span
Probe Avg
LoadDefaults
Probe Avg is a output damping parameter.
Increase to smooth out unwanted fluctuations or instability.
Reset system to defaults (amplifier and/or sensor)
Used for power related failsafe. When active the unit will switch
InputVolChk
to failsafe mode if input voltage drops below required power.
When not active unit will display ‘Input Voltage too low' on the
display if input voltage drops below required power.
25
>
<
Relay 2 Actions
Gladiator Gen 3 Microwave Series
Relay 2 Actions
Maintenance & Auto cleaner functions
Setup Example - Time Based
• The Gladiator Amplifier can use Relay 2 as a trigger
• In ‘Quickset’ Set ‘On Delay’ to 4.0 seconds - this
mechanism to notify the user or activate a cleaning
will provide a 2.0 second water blast.
system based on time or conditions within the
• In ‘Advanced’ set ‘Relay2Action' to ‘TimeOptCln’
application which require cleaning/maintenance.
• There are three software options using two different
concepts. The first concept is based on total Gain
with a ‘Clean Timer’ of 30min.
• Every 30 minutes the sensors will be sprayed for
2 seconds.
used and the second is based on a Time interval.
The selectable software options are as follows:
Setup Example - Gain Based
>
[Maintnce Chk]
See next page for Software flow chart.
<
• The unit will switch on the relay when total Gain is
greater than the CleanGainHigh % - the relay will
switch off when Gain falls below CleanGainLow %.
[GainOpt Clng]
• When total Gain exceeds the CleanGainHigh point
the unit activates the relay for 1/2 of the On Delay
time and then switches off.
• The unit will then count the Clean Time interval
time before repeat the process until total Gain is
below CleanGainLow point.
[TimeOpt Clng]
• At every Clean Time interval the unit will switch on
the relay for 1/2 of the On Delay time and then
switch off.
Other Relay2 Actions
• Relay 2 - Sets the 2nd relay to mirror the first relay action
• Failsafe - Sets the relay to trigger for a failsafe condition such as sender/receiver fail or
voltage problem
26
• In ‘Quickset’ Set ‘On Delay’ to 4.0 seconds - this will provide a 2.0 second water blast.
• In ‘Advanced’ set ‘Relay2Action to ‘GainOptCln’ with a ‘CleanGainHi’ of 80%, ‘CleanGainLo’ of 70% and ‘Clean Timer’ to 5.0min.
• This will trigger the water spray for 2 seconds when Gain goes above 80%. The spray will repeat every
5 minutes until Gain goes below 70%.
• You can view Gain while the unit is running by using
the arrow key to locate the diagnostic display.
Relay 2 Software Flow Chart
Gladiator Gen 3 Microwave Series
Relay 2 Software Flow Chart
To set spray duration for Gain and Time options (1/2 of On Delay).
Sensor Value
CAL
Unlock 0
CAL
Quickset
CAL
App Type
Cal Mount
Switch Point
On Delay Adj
CAL
On Delay Adj
CAL
Off Delay Adj
Relay Action
On Delay Adj
CAL
*Edit*
to save
Min 3.0 seconds
To set Relay 2 action for one of Time, Gain or Maintenance options.
Sensor Value
CAL
Unlock 0
CAL
Quickset
>
Advanced
Switch Mode
CAL
Relay2Action
View Log
Reset Log
Comms Type
ProbeAVG
Initilize TX
LoadDefaults
CAL
TimeOpt Cln
GainOpt Cln
CAL
Clean Time
CAL
CAL
CleanGainHi
CleanGainHi
CAL
CAL
CleanGainHi
CleanGainHi
*Edit*
*Edit*
CAL
Clean Time
*Edit*
CAL
to save
CAL
CAL
CleanGainLo
CleanGainLo
CAL
CAL
CleanGainLo
CleanGainLo
*Edit*
*Edit*
CAL
Clean Time
CAL
Clean Time
*Edit*
CAL
to save
27
Maintnce Chk
CAL
to save
Relay2
Failsafe
<
Cross-Talk Prevention / Sequencer Wiring
Gladiator Gen 3 Microwave Switch Series
Cross-Talk Prevention / Sequencer Wiring
• Up to four remote Microwave systems can be set up for anti-crosstalk.
• For two systems, one can be set to operating mode ‘Master’ and the other to operating mode ‘Slave’.
• For up to four systems, a dedicated Sequencing control unit must be used with the four systems set to operating mode ‘Slave’.
• SeeMICROWAVE
user manual
forAMPLIFIER
further information.
GLADIATOR
REMOTE
MASTER
GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE
NC
COM
NO
21
22
23
24
25
26
27
28
29
30
2
3
4
5
6
7
8
9
10
N
Ground
SENSOR
DC-In
AC-In*
Is
L1
COMMS
2
Is
1
L1
B
COMMS
SENSOR
3
DC-In
4
+ –
25
26
27
28
29
30
10
11
12
13
14
15
– +
DC-In
AC-In*
<
15
23
24
9
AC-In*
5
4-20mA (N/A)
14
22
NO
– +
4-20mA (N/A)
13
COM
15
12
6
7
8
SENSOR
COMMS
L1
14
11
–20 +21
19
NC
13
18
N
12
17
NO
11
16
COM
10
8
BROWN
7
WHITE
6
+ –
>
RELAY 2
NC
9
1
TEST IN
NO
30
L1
COM
29
RELAY 1
B
NC
28
MASTER OUT
NO
27
N
COM
26
RED
NC
25
A
TEST IN
24
15
23
AC-In*
5
4-20mA (N/A)
MASTER OUT
SLAVE IN
14
22
BLUE
+ –
13
DC-In
4
BLACK
3
RED
Is
2
12
N
11
–20 +21
19
COMMS
1
BROWN
BLACK
RED
SENSOR
18
A
17
B
BROWN
16
MIC-SENDER
BROWN
WHITE
4-20mA (N/A)
NO
10
20
SLAVE IN
9
19
WHITE
8
COM
7
18
BROWN
6
17
BLACK
5
16
RELAY 2
BLUE
4
RELAY 1
BLACK
3
TEST IN
2
+ –
NC
30
A
29
RED
28
MASTER OUT
NO
27
SLAVE IN
COM
26
MIC-SENDER
GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE
B
NC
25
BROWN
NO
24
WHITE
COM
23
GLADIATOR MICROWAVE REMOTE AMPLIFIER MASTER
BROWN
TEST IN
22
BLACK
MASTER OUT
NC
21
BLUE
SLAVE IN
20
RED
BROWN
19
RELAY 2
RED
BLACK
18
RELAY 1
BLACK
RED
17
RED
Ground
Sequencer / Slave Wiring
GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE
COM
NO
22
23
24
25
26
27
28
29
30
2
3
4
5
6
7
8
9
10
com
Tx
com
Tx
com
Tx
com
Tx
TO
SLAVE 4
com
Tx
com
Tx
GMSEQ MICROWAVE SEQUENCER
CH1
CH2
CH3
CH4
TO
SLAVE 3
TO
SLAVE 4
4
5
NO
4-20mA (N/A)
COMMS
TO
SLAVE 3
3
DC-In
COM
DC-In
AC-In*
GMSEQ
MICROWAVE
SEQUENCER
CH1
CH2
CH3
CH4
2
+ –
14
22
25
26
27
28
29
30
10
11
12
13
14
15
– +
L1
1
15
13
NC
14
12
–20 +21
N
13
11
19
NO
12
18
COMMS
Is
11
– +
17
SENSOR
L1
10
N
9
com
Tx
SENSOR
8
A
7
16
COM
Is
L1
4-20mA (N/A)
B
6
+ –
NC
1
RELAY 2
A
30
TEST IN
NO
29
DC-In
AC-In*
15
23
L1
COM
28
RELAY 1
24
9
AC-In*
6
7
SENSOR
8
B
NC
27
MASTER OUT
NO
26
MIC-SENDER
RED
COM
TEST IN
NC
MASTER OUT
BROWN
SLAVE IN
N
24
AC-In*
BROWN
5
25
15
23
com
Tx
4-20mA (N/A)
4
14
22
WHITE
3
13
DC-In
RED
Is
2
12
–20 +21
BLUE
COMMS
+ –
BLACK
RED
11
19
BLACK
SENSOR
18
A
17
B
BROWN
16
1
28
21
SLAVE IN
WHITE
4-20mA (N/A)
20
N
10
19
WHITE
9
18
BROWN
8
NC
7
NO
6
COM
5
17
BROWN
4
16
RELAY 2
BLACK
3
RELAY 1
BLUE
2
+ –
NC
30
A
29
RED
28
TEST IN
NO
27
MIC-SENDER
GLADIATOR MICROWAVE REMOTE AMPLIFIER
SLAVE
B
COM
26
MASTER OUT
NC
25
SLAVE IN
NO
24
GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE
BROWN
COM
23
WHITE
NC
22
BROWN
TEST IN
21
BLACK
MASTER OUT
20
BLUE
SLAVE IN
19
BLACK
BROWN
18
RELAY 2
RED
BLACK
17
RELAY 1
RED
RED
Is
1
MIC-SENDER
RELAY 2
RED
16
RELAY 1
BLUE
MIC-SENDER
BLACK
GLADIATOR MICROWAVE REMOTE AMPLIFIER SLAVE
BLACK
Is
1
MIC-SENDER
RELAY 2
BLUE
16
RELAY 1
BLACK
MIC-SENDER
A
Master / Slave Wiring
COMMS
Integral Test Switch
Gladiator Gen 3 Microwave Series
Integral Receiver Test Switch Functions
The test terminal has two potential modes of operation for Integral units and always operates in the test input
mode for Remote units. Remote units have a separate, failsafe relay contact, which is always functional.
Test Input Mode
Test Switch: ON
Test terminal acts as an input for remote testing of the instrument’s switching function. Used to check for
malfunction of unit from a remote position, PLC, SCADA etc.
Receiver Terminal Block
Test Input from PLC/SCADA/DCS Digital Output
4
PLC / SCADA / DCS Output
Test
>
<
!
PLC/SCADA/DCS GROUND MUST
CONNECT BACK TO GLADIATOR
GROUND OR DC ‘-’ TERMINALS
Receiver Terminal Block
Operator Controlled Press To Test
4
Externally provided
test button
!
Failsafe Output Mode
Test
EXTERNAL PUSH BUTTON GROUND
MUST CONNECT BACK TO GLADIATOR
GROUND OR DC ‘-’ TERMINALS
Test Switch: OFF
Test terminal will provide an output which is able to switch an external failsafe relay or PLC/SCADA/DCS
input. During normal system operation this terminal will internally switch a solid state (transistor) output to
ground (or DC ‘-’). If power fails or an internal system failure occurs, the terminal will act as an open circuit.
To switch an external relay
To a PLC input
+12-24Vdc
Receiver
Terminal
Block
Test
Test
4
Receiver
Terminal
Block
29
Coil rating
500mW max
or 50mA max
Relay will turn on during
normal system operation
or off in failed or unpowered
conditions.
4
12-24Vdc
max 50mA
Pull up
PLC
SCADA
DCS Input
Input will detect ‘0’ state during normal system
operation, or ‘1’ in failed or unpowered conditions.
Troubleshooting
Gladiator Gen 3 Microwave Series
Troubleshooting
Erratic / non responsive Sensor% value
Manual blockage switch testing
• For older hardware, ensure the Sender is set to the • In some modes the Hawk Microwave system will be
correct mode via switch on facia (INT for Integral, difficult to switch test using small objects. You
REM for remote).
must completely cover the Sender and Receiver
• Press and hold the 'Test' button on the Sender unit. with solid materials (such as bags of process
functions correctly the system is operating correctly.
• You can also view the 'Recover Gain' Diagnostic • If the system is operating correctly increase
which will respond while the signal begins to be This will force the Sensor % to read 99-100%. If this material).
'Probe Avg' to create a smoother displayed value.
blocked by objects.
• There may be build up or signal loss if the unit is Relays & LCD intermittently dimming and
not able to hold a 0% value this indicates signal loss dropping out.
or not enough Gain is available. Check for build up,
• Check incoming voltage with a multimeter in line. obstructions, or choose a new App Type / perform
Confirm it is as per Specification
new Cal Mount.
• If the unit is AC powered put a multimeter over the If the system does not respond to pressing the
DC +/- terminals. The unit generates a diagnostic 'Test' button
DC voltage in these terminals. If powered by AC.
• There may be a potential hardware fault.
This should read at least 8V consistently.
• First confirm wiring runs are correct (see Error 01
• If this is unstable and dropping below 7V while
codes for further information on wiring checks).
your incoming AC is stable there is likely a problem
• Change the Receiver, Sender, Amplifier in this order.
If this does not resolve the issue, remove hardware
and perform isolated bench test on the units.
Switch Testing
• If the Sensor% reads 0% this means full signal is
present and the system is operating correctly.
Use the 'Test' button on the Sender to test the relay
action.
30
with the internal power supply. Contact your local
distributor or HAWK.
>
<
Troubleshooting
Gladiator Gen 3 Microwave Series
Error Codes
Error 01:
Error 02:
• Amplifier/Transmitter can not communicate with • Error Codes can also indicate communication data sender/receiver.
failures or corruption between Amplifier and
• Error No 01 is displayed on power up with a reset Sender/Receiver.
loop or after unit has successfully operated and • Ensure any junction box / wiring extensions are as subsequently failed.
per Hawk wiring guide. Make sure wiring is correct • Check wiring terminals for a loose or incorrect especially look to the screen (earth).
connection (including junction box / cable Error 03:
extensions).
• Check the cables for any signs of damage.
• Incorrect comms module selected
(eg Profibus, FF). Check part number to confirm • Ensure any customer supplied cable meets HAWK communications options (All units are Modbus as specifications.
default)
• Ensure correct power is applied to the correct
Error 04:
terminals. DC only version units will not support AC.
• Use a multimeter to check voltage supply for the Remote Sender & Receiver on the red/black labeled terminals of the Amplifier. You should get approximately as below:
Sender 24.0VDC
Receiver 9-10VDC
• Disconnect Sender and Receiver from amplifier and use a multimeter to check kohm resistance values (approximate) across the following wires.
Sender:
• Brown: Black 200-230kohm
Receiver:
• White: Blue 27-32kohm
• Black: White or Blue 13-16kohm
• Brown: Blue or White 70-80kohm
• Brown: Black 60-70kohm
31
• Amplifier is programmed with incorrect software. Contact your local support.
>
<
Safety Information
Gladiator Gen 3 Microwave Series
FCC Regulations
Qualifications
Requirements
The Federal Communications Commission imposes
(A) OSHA - 10mW/cm2of radiated power.
strict requirements on radiating sources such as the
(B) ANSI - 5mW/cm2 of radiated power.
GSA, GMS, GMRR, GMSR, Microwave Systems.
The Hawk Gladiator Microwave Systems have
This unit is tested to, and meets these requirements,
which include operating frequency and stability,
harmonic and spurious generations and power output.
The HAWK Gladiator Microwave System complies with
FCC Rules Part 15 for industrial controls. No licenses
or approvals are required to use the system.
32
approximately 20µW/cm2 of radiated power.
Note: The HAWK Microwave Pulse Systems are
well below the stringent safety standards required by
both the above governing bodies. It is regarded as a
SAFE level control and may be used with no special
precautions.
>
<
Part Numbering
Gladiator Gen 3 Microwave Series
Remote Version
Remote Amplifier
GSA Gladiator Amplifier (compatible with all Gladiator products), Modbus
Housing
S Polycarbonate
Power Supply
B 12-30 VDC
C 30-48VDC and 48-90VAC
U 12-30VDC and 90-260VAC
Output Options
>
S 2 Relays (relay 1 primary switch, relay 2 secondary switch OR Failsafe / Cleaner / Maintenance alarm)
<
X Option ‘S’ plus 4-20mA output
Approval
A22 ATEX Grp II Cat 3 GD T85°C IP67 Tamb -40°C to 70°C
GSA S U S
Remote Sender / Receiver
Connection Cable
GMSB
Gladiator Microwave Sender
GMRR Gladiator Microwave Remote Receiver
CA-GMR Pre-cut cable for remote sender or receiver
Frequency
1 10.525 GHz
Transducer Facing Material Selection
0 UHMW Polyethylene
1 PTFE Teflon
Transducer Housing Material
1 Aluminium / Mild Steel
2 316L Stainless Steel
1010mcable
20 20m cable
30 30m cable
50 50m cable
100100mcable
CA-GMR 10
Output Option
X Not Required - Outputs generated from GSA amplifier
Lengths above
100m available via
special order
Approval Standard
X
A22 ATEX Grp II Cat 3 GD T85°C IP67 Tamb -40°C to 70°C
GMSB 1 0 X
33
1
X
Not Required
Part Numbering
Gladiator Gen 3 Microwave Series
Integral Version
GMS Gladiator Microwave Sender
GMSR Gladiator Microwave Smart (Integral) Receiver
Power Supply
B 12-30 VDC
U 12-30VDC and 90-260VAC
Frequency
1 10.525 GHz
Transducer Facing Material Selection
0 UHMW Polyethylene
1 PTFE Teflon
Transducer Housing Material
1 Aluminium / Mild Steel
2 Full stainless steel
Output Option
X Not Required for Sender units
S Switch, 1 output relay with
Modbus for Receiver units
Approval Standard
X Not Required
A22 ATEX Grp II Cat 3 GD
T85°C IP67 Tamb
-40°C to 70°C
GMSR B 1 0 1 S X
HAWKLink Modem
Model
HL HAWKLink
Type
R Remote stand alone system
Power Supply
B 12-30VDC
U 12-30VDC and 90-260VAC
Network Type
G3 3G
Simcard
S3 Australian Simcard expires
after 3 month
S12 Australian Simcard expires
after 12 month
X Not Required
(customer supplied data enabled
simcard)
HL RUG3
S3
34
MA Mounting Accessory
Type
0
3” Weldment, each
3
3” UHMW Window & Weldment each
4
4” UHMW Window & Weldment each
5
6” UHMW Window & Weldment each
6
3” PTFE Window & Weldment each
7
4” PTFE Window & Weldment each
8
6” PTFE Window & Weldment each
9
9’ x 4,5” fire brick assembly each
10
6” x 4” ceramic brick assembly each
11
Shock/vibration insulation mounts pack of 4
12
Adjustable mounting bracket
>
(UHMW window) each
13
Adjustable mounting bracket
<
(PTFE window) each
15
Flanged Focaliser tube (extension pipe)
(mild steel)
16
3” Ceramic Window & Weldment each
17
4” Ceramic Window & 4” Weldment each
18
4” Microwave Weldment only each
19
3” Stainless steel Weldment only for
UHMW each
20
4” UHMW Window only each
21
3” UHMW Window only each
22
4” Stainless steel Weldment only for
UHMW each
25 Flanged Focaliser tube (extension pipe)
(316L)
20-P1 4" UHMW Window with 40mm
insertion depth (fits 4" Weldment)
MA4
GMSEQ Gladiator Microwave Sequencer
Power Supply
B 12-30VDC
C 30-48VDC and 48-90VAC
U 12-30VDC and 90-260VAC
GMSEQ U
HAWKlink-USB HAWKlink USB PC connector for GosHawkII
Specifications
Gladiator Gen 3 Microwave Series
Operating Voltage
• Integral 12-30VDC / Remote 12-30VDC
(residual ripple no greater than 100mV)
• Integral 80-260VAC / Remote 90-260VAC 50 / 60Hz.
Power Consumption
• <0.8W @ 24VDC
• <5VA @ 240VAC
• <3VA @ 115VAC
Communications
• GosHawk, Modbus • 4-20mA
• Multidrop mode can address 1-250 units over 4 wires.
Relay Output: (1) SMART (2) Remote
• Form ‘C’ (SPDT) contacts, rated 5A at 240VAC resistive
• Remote fail-safe test facility for one relay.
Operating Temperature
• Remote electronics -40°C (-40°F) to 80°C (176°F)
• Integral Units -30°C (-20°F) to 65°C (150°F)*
• Remote Sensors -30°C (-20°F) to 65°C (150°F)*.
*For higher temperature applications, remote mounting with refractory windows is necessary.
Power Density
• Rated from emitter to receiver at approximately 20µW/cm²
• Complies with FCC Title Rules Part 15 (Beam Blockage)
• Caution sign posting not required.
Transmitted Signal
• Circular transmission polarity
• Frequency: 10.525GHz • Power: +20dBm/100mW • Sensitivity -95dBm
• Beam width 25º
Fail-Safe
• Selectable - presence or absence of material
• High level fail-safe:
relay is activated when material is present
• Low level fail-safe:
relay is activated when no material is present.
Alternate cable type between Amplifier and
Sensors
• 6 or 8 conductor (5 used) shielded twisted pair
instrument cable
• Conductor size dependent on cable length
• BELDEN 3120A, DEKORON or equivalent
• Max: BELDEN 3120A = 500m (1640 ft). 3 pairs,
1 conductor not used
• Max: DEKORON IED183AA004 = 350m (1150 ft).
4 pairs, 3 conductors not used.
Maximum Operating Pressure
• 2 BAR
Display (Remote version only)
>
• 2 line x 12 character alphanumeric LCD
• Backlight standard.
<
Memory - Remote
• Non-Volatile (No backup battery required)
• >10 years data retention.
Enclosure Sealing
• Integral Sensors IP67
• Remote Electronics IP65 (NEMA 4x)
• Remote Sensors IP67.
Cable Entries
• Remote Sensors:
1xM20 Gland / 3/4” NPTF threaded adaptor
• Remote Amplifier:
4x20mm (0.8”), 1x16mm (0.6”) knock outs
• Integral Units:
2xM20 Glands / 3/4” NPTF threaded adaptors.
Mounting
• 3” male NPT thread or four 10mm (0.4”) holes in flange
• MA12 / MA13 adjustable mounting bracket
Environment Seal
Sender / Receiver to Amplifier Separation
• 3”, 4” and 6” weldments for standard mounting on vessel wall with PTFE and UHMW windows
• Flange for mounting separate from vessel wall - isolation shock mounts are available
• Ceramic window assemblies
• Firebrick window assemblies available on custom basis
• Waveguides - custom assemblies available for high temperature and limited access applications.
• Up to 500m (1640ft) using specified extension cable.
Weight
Range
• Maximum range under ideal conditions: 1200m (656ft)
• Minimum range under ideal conditions: 10cm (4 inches).
Note: Minimum ranges are dependent on application
conductivity.
• GSA 1kg 35
• GMS 5kg • GMR 5kg
A Higher Level of Performance
Gladiator Gen 3 Microwave Series
HAWK, Since 1988
Remote Innovation
Hawk Measurement Systems Pty Ltd (HAWK) was
established in 1988. It's founding members saw the
universal requirement of various industries requiring
improved process control and efficiency in their
HAWK understands the need for immediate technical
assistance.
We Can Help
HAWK understands the difficulties customers face
when seeking accurate level measurement. Every
application is different, involving a multitude of
environmental factors. This is where HAWK excels.
Our aim is to ensure that customers not only feel
comfortable with our technology, but also to ensure a
consistent and reliable solution is in place for the long
term. We believe that a combination of application
and product expertise, as well as forward thinking
and proactive support policies are the foundation of
successful customer-supplier relationships.
Progressive Technical Support
HAWK believes that the future of the Level
Measurement Industry revolves around the quality
of pre and post sales - support. Our aim is for all
sales & support staff to be product experts, and more
importantly application experts making our customers
applications as efficient and consistent as possible.
happen; not days or weeks later.
Knowledge Sharing
HAWK believes that knowledge sharing is key to
creating long term relationships. Empowering our
customers and our worldwide distribution network,
whilst being available at all times to lend a helping
hand, is the perfect recipe for long term solutions and
relationships. HAWK openly extends an invitation
to share our 25 plus years of level measurement
experience, and ensure that your day to day
processes are efficient, understood, and always
working.
All company or product names are registered trademarks or
trademarks of their respective owners.
Hawk Measurement Systems
Hawk Measurement
(Head Office)
96 Glenn Street
Lawrence, MA 01843, USA
15 - 17 Maurice Court
Nunawading VIC 3131, AUSTRALIA
Phone: +61 3 9873 4750
Fax: +61 3 9873 4538
[email protected]
Phone: +1 888 HAWKLEVEL (1-888-429-5538)
Phone: +1 978 304 3000
Fax: +1 978 304 1462
[email protected]
For more information and global representatives: www.hawkmeasure.com
36
<
DOC-3MIC-SWITCH-MAN 1214
operations.
The HAWKLink 3G communication device allows
any computer with internet access and our free
GosHawk diagnostic & calibration software; to dial in,
calibrate, test, and check the performance of HAWK
products. This innovative system allows our Global
Support Team to assist with commissioning and
after sales service of HAWK equipment worldwide.
Measurement problems are addressed as they